Method of forming complementary concrete dies



Jan. 2, 1945. J. H. BROWN 2,366,435

METHOD .OF FORMING COMPLEMENTARY CONCRETE DIES- ATTE! RN EYB Jan. 2,1945. 1 H BROWN METHOD 0F EORMING GOMPLEMENTARY CONCRETE DIES Filed May1, 1942 6 Sheets-Sheet 2 /7/ 1z/.// ////////w/.//././l

' JNVENToR. cfameshroww Jan. 2, 1945. '.1. H. BROWN METHOD OF FORMINGCOMPLEMENTARY CONCRETE DIES Filed May l, 1942 6 Sheets-Sheet 3 INVENTOR.

Jamie/,5* H. rown mm @o D QN 3, U O 1MM .n Jv@ r y l* m. l n. ,l ff QJ@u E LQ o mt C @N mm Jam 2, 1945- J. H. BROWN METHOD OF FORMINGCOMPLEMENTARY CONCRETE DIES Filed May l, 1942 -6 Sheets-Sheet 4 IN V ENTOR.

Cfczm @6J-. ,Brown mja/mf@ A'ITEI RN EYS Jan. 2, 1945.

J. H. BROWN METHOD 0F FORMING COMPLEMENTARY CONCRETE DIES Filed May l,1942 6 Sheets-Sheet 5 INVENToR.

cfam 95H. Zro urn ATTD R N EYE IJan. 2, 1945. J. H. BROWN METHOD OFFORMING COMPLEMENTARY CONCRETE'DIE'S 6 sheets-sheet e Filed May l, 1942v'Pateill Jan. 2, 1945.

f ,uuu-ED CONCRETE DIES James Hugh Brown, Seattle, Wash. Application Mayll, 1942, Serial No. 441,415 k 4 claims. (Cms- 155) My invention relatesto the shaping and contouring of laminated wood, ply wood or veneer,

and the molding of plastic materials, and has among its objects andadvantages the provision of an improved mold and a method of making thesame. i

Considerable difficulty has been experiencedy in the construction ofiron and steel molds in.

the nature of a shoe and a die for bending and shaping structuralmaterials, particularly in cases where the shapes are in the nature ofbends or geometrical curves in both single and compound curvatures. Inthe case of iron or steel., each mold part has to be separately castfrom a separate pattern.H This method does not insure, in the molding ofeach part, a perfect conformity and contour. Such methods require muchexpensive machine work on both the die and the shoe in order that theyshall closely conform to and contour with each other. Then, too, thereis the further problem of warping and shrinking peculiar to metallicshoes and dies.

Accordingly, an object of my invention is to provide a novel shoe anddie combination wherein the two parts may be accurately shaped .toclosely conform to and contour one with the other, and in which theparts are`constructed of material which entirely eliminatesobjectionable warpage and shrinkage.

A further object is to provide a mold `cornprising coacting die and shoeunits formed of concrete or other initially plastic material wherein theshoe and the die are provided with internal and external reinforcingmeans, and in which the die and the shoe are provided with means forcirculating aheating and drying or cooling medium therethrough forsubjecting the work being bent or shaped to the required teml peratureconditions.

shaped coacting fa'ce on the second unit, to-

gether with the use yof a thin -separator between the two units tofacilitate separation thereof upon hardening of the second unit.

Another object is to provide a novel mold wherein a ilexible pressure orsuction responsive means may be employed in' connection with a rigidmold member to bend or shape construction materials to the contour ofIthe rigid mold member.

In the accompanying drawings: Figure l is a perspective view of a moldin accordance with my invention;

Figure 1a is a sectional detail view vof a portion of one of the mo'ldclamps:

Figure 1b ,is a perspective view of a form for pouring the concrete;

Figure 2'ls a transverse sectional view of a shoe and die mold contouredin accordance` with Figure lbut in which the shoe and die are providedwith internal and external reinforcement;

Figure 3 is a longitudinal sectional` view of the structure of Figure 2;

Figure 4 is a top plan view;

Figure 5 is a detail view of one of the work or material guides; I

Figure 6 is a view similar to Figure 5 but illustrating fingers attachedto the guide for holding the elements of a laminated assembly in olsetrelationship one with the other;

Figure '7 is a view illustrating a shoe member in association with asuction responsive wall for shaping and bending construction material;

Figure 8 is a sectional view of the shoe in association with a pressureenvelope for bending and shaping construction material;

Figure 9 is a sectional view of a shoe illustrating the manner in whicha shoe facing of different contour may be mounted' thereon;

Figure 10 is a sectional view of a die illustrating internal andexternal reinforcement therefor;

Figure 11 is a perspective view of a series of shoe and die sectionsassembled upon a common base for coaction on a single piece ofconstruction material together with means for circulating a heating orcooling medium through the respective shoe and die sections;

Figure l2 is an end view of a shoe and die unit wherein the shaping andbending faces are of different radii to bend and shape work having acurved contour of uniform thickness throughout.

its entire body;

Figure 13 illustrates a`further modication in the work or material guidemeans;

Figure 14 is a top view of one end of the structure of Figure 13;

Figure l5 is a view of one guide member; Figure 16 is a. view of acompanion guide mtmbel', and.

In the embodiment selected for illustration, I ,i

make use of a concrete shoe I and a concrete die I2. The shoe I0 isprovided with a shaping and bending face I4 and the die I2 is providedwith a correspondingly shaped face I6. Figure 1 illustrates sheets I8 ofply wood arranged between the faces I4 and I6 to be bent to the contourof the faces and united into a unitary structure by grooved jointsbetween the respective ply 4wood sheets. A sheet 20 of pliable material,such as rubber, is positioned between the face I4 and the lowermost plywood sheet I3. A similar pliable sheet 22 is placed'between the face I6and the uppermost ply wood sheet I8. I'he sheets 20 and 22 are employedonly in such cases as where the materials being fabricated arecharacterized by slight or pronounced irregularities which, preventeil'ective pressure from being applied throughout the entire area jofthe assembly. In most cases tlf@ pliable sheets may be dispensed withand thestructural materials arranged for direct engagement with the twoforming faces I4 and I6.

After application of glue to the engaging faces of the sheets I8,pressure is brought to bear on the assembly through tightening of nuts24 on Arods 26 passing through openings in lugs 28 partially embedded inthe concrete of the respective shoe and die I0 and I2. This'pressurecondition serves as a holding means until such time as the requiredpressure is applied by means of hydraulic or other external means oflike force and strength. The assembled" sheets are maintained K underpressure until the glue has dried thoroughly. When the glue has beenproperly dried, the sheets I8 are secured firmly one to the other andthe assembly has a contour conforming to the faces I4 and I6.

In order to position and retain the die I2 in true vertical relationshipwith the shoe I0, guide rods 30 are slipped through eyes 32 in both theshoe and the die, which rods are preferably hooked at 34 to engage theupper face of the die I2 to be restrainedy from downward longitudinalmovement. The eyes 32 are also partly embedded in the concrete of theshoe and the die.

In securing the sheets I8 into a unitary struc-` ture by means of glue,the glue frequently acts as a lubricant which causes the sheets to shiftlaterally when pressure is applied to the assembly. In cases where it isdesirable tol restrain the sheets from such relativerlateraldisplacement, aligning bars 36 are brought into engageing and shapingmaterials of different total thick- IIESSBS.

In cases where it is desirable to arrange theedges of the sheets I8 inoffset relationship, spacing fingers 50, see Figure 6, may be employed.Each group of fingers 50 is carried by a bar 52 corresponding to one ofthe bars 38, and the bars 50 are adjustable horizontally and verticallythrough the medium of'bolts 54 which pass through a slot 56 in the bar52 and through slots 58 in the respective fingers. The bars 52 may besubstituted for the bars 36 in the eyes 40.

assunse u The loffset arrangement of the sheets I8 in Figure 6 providesan edge contour wli'ereinlthe respective sheets of one assembly may bejoined in overlapping relationship with the sheets in another suchassembly to provide a strong joint.

Frequently it is desirable to heat the shoel and the die for work dryingpurposes. Figures 1 and 4 illustrate the shoe andthe die as beingprovided withv steam pipes 60 embedded in the material of the respectivebodies. Oneor more such pipes may be embedded in each unit, as theparticular situation may demand or require, with the pipes bent tozigzag contour, and with the ends of the" pipes projecting sufcientlyfar from the units to provide connections for steam conduits. A coolingmedium may be circulated through the pipes if a low temperaturecondition is desired. To facilitate handling of the shoe and the die,each is provided with two pipes 82 embedded therein and extending thefull width thereof so that lifting rods may be inserted in the pipes forconnection with a lifting hoist. The lifting rods are indicated at 64 indotted lines in Figure 4.

Figure 1b illustrates a box or form 66 which may be placed on a floor ortable 68. The upper faces 'I0 of the side Wallsy 12 are contoured toproduce the curvature, single or compound, desired. The concrete ispoured into the box 66 and the face of the shoe shaped to the desiredcontour, with the faces 10 acting as a guide or aid \\in shaping theshoe face. When the shoe is solidified, the box 66 is removedfrom theshoe by unloosening the tie rods 14. 'Ihe tie rods are again tightened.afterthe removal of the box from the shoe, and the box is reversed andplaced directly over the shoe, with a sheet of oiled paper on the faceof the shoe as a separating means. Concrete is then poured into the boxto produce a die having a contour conforming exactly to the face of theshoe, since the shoe then constitutes the bottom of the box.

Figures 2 and 3 illustrates a shoe 16 and a die 'I8 of the same contoursas the shoe I0 and the die I2. In the construction of Figures 2 and 3,both the shoe and the die are provided with a plurality of parallelreinforcing members 80 in the nature of I beams embedded in the concreteof the respective bodies. Additional reinforcing rods 82 are alsoembedded in the shoe and the die in right angular relationship with theI beams 80.

The shoe 16 and the die 'I8 are provided with means to resist chippingand cracking of the concrete about the respective bending and shapingfaces 84 and 86, respectively. This reinforcementl comprises steelframes 88 engaging the four faces 90 on the respective shoe and diebodies. The frames 88 terminate slightly short of the respective faces84 and 86, and each frame includes a narrow ange 82 lying in engagementwith the rear face of its respective concrete body. Key flanges 94 areformed on each of the frames 88 to be embedded in the concrete for rmlyanchoring the frame. The lugs 96 corresponding ,to the lugs 28 arecarried by the frames 88. y, .Y

Both the shoe and the die of Figures 2 and 3 are provided with steampipes 98. The frames are also provided with eyes I00 corresponding tothe eyes 32 and 46 for supporting aligning rods |02 and guide rodsy I 04of the type illustrated at 30 and 44, respectively, in. Figure 1. Liftpipes |06 are also embedded in the concrete of the shoe and the die.

Figure '1 illustrates a concrete shoe |08 lying assaut l l in a steelpan provided with a flange ||2 about its open end. Enclosing the upperportion of the shoe |08 is a flexible or rubber cap ||4 secured betweenthe flanges 2 and bars ||8 by bolts ||8L The work to be shaped isindicated at as lying on the contour face 22 of the shoe |08 and insidethe cap ||4. A pipe |24 is attached to the cap ||4 and has communicationwith the jspace between the cap and the shoe. This pipe is connectedwith a vacuum Ipump (not shown) for bringing the cap |4 into pressureengagement with the work to bend it to the contour face |22 throughevacuation of the air in the work space.

Figure 8 illustrates a shoe |26 having lugs |28 partly embedded in thematerial of the `shoe for anchoring purposes. To the lugs |28 isdetachably connected a steel cap |30 by bolts |32. The work |34 islocated between the contour face |36 of the shoe and a flexible bag orenvelope |38 lying inside the cap |30. A pipe |40 extends through thecap |30 and has communication with the bag |38 for admitting air underpressure to bend the work to the contour face |36. The cap |30 providesan 'enclosure for the bag |38 BO that expansion thereof connes itsinflation in a work direction to effectively contour the work to theface |36.

Figure 9 illustrates means for shaping a shoe having such extremecontours as to necessitate the formation of a patternrto mold the faceof the shoe. In the form |42 is placed a .pattern |44 having ashoe-shaping face |46 characterized by sharp curves |48. The face |46 istreated with wax, grease or the like and the concrete is poured into theform and over the pattern |44, which side edges and face |54 oppositethe contour face |56. Reinforcing ribs |58 are formed on the .innerfaces of the jacket |52 for strengthening the body-|50. I

In Figure 11, a series of shoes |60 and a series of dies |62 arearranged in abutting relationship upon a common base |64 for shaping arelatively large piece of work |66. The shoes and dies may` ybeidentical with those of Figure 1 with respect to clamps, aligning means,guides and.heating or cooling means, with the exception that thesedevices should be so arranged as to permit end to end engagement betweenthe respective shoe and die elements in the series, thereby providingcontinuous pressure faces.

'I'he mold of Figure 12 comprises a shoev |68 having a face contour |10and a die |12 having a,

face contour |14 coacting with the face |10 to bend plywood y|16 or thelike for the construction of tank walls and similar structures. The face|14 is characterized Y.by a smaller diameter than the face |10 so as toprovide uniform spacing between the two faces. In the form of Figure 12the two faces |10 and |14 are independently shaped to size and contour,since one face can not be shaped by pouring concrete over the other facebecause oi.' the difference in diameters of the respective faces. Boththe die and the shoe may be provided with conduits for a heating orcooling medium, as well as the clamps," guides and the aligning means ofFigure ,1.

Figures 13 through 16 illustrate a further modification in the workguiding means. Figure 13 illu'stratesa plurality of sheets |16 arrangedin overlapping relationship between the shoe sec: tion |18 and the diesection'l80, as when being glued or cemented into -a unitary structure.To the shoe-` section |18 are connected two gage brackets |82, whichbrackets are located on opposite faces of the shoe and secured theretoby bolts |84 embedded in the material of the shoe. Two similar gagebrackets |88 are attached to the die by bolts |88. .The brackets |86 arelocated vertically above the brackets |02. Each bracket is provided withtwo bores [90,l the bores in the brackets |82 being respectivelyco-axially arranged with the bores in the brackets |86. Gage guide rods|92 are slipped through the aligned bores and preferably made secure tothe brackets |82 by set screws |94. f

A gage holding body |96 is mounted upon each set of rods |92. Bores |98are provided in the bodies |96 for loosely receiving the rods |92.

Each of the bodies |96 is provided with a trans-A verserectangularly-shaped opening 200.

A tongue-forming guide 202 is inserted in the-slot 200 in one body 96and made secure by a set screw 204. This guide is provided withshoulders 206 so spaced and arranged as to abut the sheets |16 in thelaterally offset relationship of Figure 13 to provide'a tongue formation208. Guide 200 extends to a position between the shoe 18 and the die |80and its vertical dimension is narrower than the spacing between the shoeand the die to provide clearance in the closest spacing of the shoe andthe die.

A work guide 2|0 is inserted in the other body |96 and may be madesecure by a set screw 2| 2. This work guide is provided with shoulders2|4 so arranged as to engage the opposite edges of the sheets |16 whenthe latter are relatively laterally offset in the manner of Figure 13and in conformity with the work guide 202. I'he work guide 2 I0 is alsonarrower than the-closest spacing between the shoe and the die, andeither work guide 202 or 2|0 may be adjusted to bring the edgesl of thesheets 18 into desired holding engagement with the respective shoulders206 and 2|4 to restrain the sheets |16 from relative lateral shiftingwhen pressure is applied to the assembly. While the set screws |94firmly secure the rods |92 against vertical movement, the brackets |86are free to move longitudinally on the rods |92, as when the die |80 ismoved vertically relatively to the shoe |18. When the sheets |16 havebeen thoroughly secured into a unitary assembly, the assembly ischaracterized by a tongue 208 along one edge and a groove formation 2|6along its opposite edge for receiving the tongue formation 208 onanother assembly. Thus sections 0f assemblies may be effectively joinedone to the other and with the respective sheets of the assembliesoverlapping one with the other.

While I have employed specic designs to illustrate the purpose, scopeand function of my invention, I am not to be restricted to these,provided always, of course, that I confine such other designs as I mayemploy within the scope and principle of my invention.

Without further elaboration, the foregoing will so fully illustrate myinvention, that others may,

` quently separating the die from the shoe at their same for use undervarious conditions of service.

I claim:l

l. The methodA of forming a shaping mold comprising a concrete shoeinthe nature of a monolith and having sides and ends, and a top andbottom face, thewhole of the top face constituting a work-shaping faceand a concrete die in the nature oi' a monolith and havingJ sides andends, and a top and bottom, the whole of the bottom. face of whichconstituting a work-shaping face which consists in preparing a formhaving an edge contour conforming to the predetermined perimetricalcontour of the work-shaping face ofthe shoe, pouring concrete into saidform and shaping the face of the concrete to said edge contour and thepredetermined face contour of the shoe and allowing the concrete to set,remov-` ing the form from the hardened shoe, applying a separator mediumupon the work-shaping 'face of the shoe, arranging the form upon theshoe, pouring concrete into the form to form the die with a work-shapingface' the whole of which contoured from the work-shaping face of theshoe, allowing the die to harden. and subsequently L separating the diefrom the shoe at their juncture with said separator medium.

2. 'I'he method of forming a shaping mold juncture with said separatormedium.

3. The method of forming a lshaping` mold comprising a concrete shoe inthe nature yof a monolith having a work-shaping face and a concrete diein the nature oi' a monolith having an identical work-shaping face whichcomprises forming a pattern contoured to the work-shaping face of theshoe, applying a separating medium on the pattern, placing the patternin a form and pouring the concrete upon the pattern to contour thework-shapingy face of the shoe, allowing the concrete to set, removingthe shoe from the patl tern and applying la separator medium to thework-shaping Aface of the shoe, pouring the concrete of the die upon thework-shaping face of the shoe to shape the work-shaping face of the diein conformity with the work-shaping face of the shoe, allowing theconcrete of the die to set, and subsequently separating the die from theshoe at their juncture with said separator medium.

4. The method of forming complementary shoe and die sections each havinga monolithic char-y acter' of/a plastic shaping mold having co-actingwork-shaping faces which comprises molding' one section as a unit in aform having the top edges conforming to the edge contour of a. selectedwork-shaping face, placing a separator medium on the uppermostwork-shaping face of the section, removing the said form from the moldedsection, and mounting said form in reversed position for molding thecomplementarysection as a unit on the first section and the separatorthereon so that the lowermost work-shaping face of the upper sectionwill accurately conform'to the work-shaping face of the bottom section.

JAMES HUGH BROWN.

